Aventics Powerlink 580 User manual

580 PowerlinkTM
Technical Manual
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Conditions For Use of This Product
AVENTICSTM G3 Manifold ("the PRODUCT") SHALL NOT BE USED IN CONDITIONS where any problem, fault or failure
occurring in the PRODUCT may lead to any incident resulting in damage to property, serious injury or loss of life and where
the end user does not have appropriate external backups and fail-safe measures incorporated within the systems that the
PRODUCT is used.
The PRODUCT has been designed and manufactured for use in general industries. Therefore, the PRODUCT and related
document(s) are not for use in any nuclear and/or medical related applications.
For avoidance of doubt, AVENTICS and its affiliated companies shall have no responsibility or liability including but not
limited to any and all responsibility or liability based on contract, warranty, tort, product liability for any injury or death
to persons, loss or damage to property caused by the product that are operated or used in application not intended or
excluded by instructions, precautions or warnings contained in AVENTICS documentation including any Technical, User,
Instruction, Safety manuals or bulletins.
Intended Use of This Product
AVENTICS valve systems or I/O stand-alone systems with integrated fieldbus communications are designed to be used on
specific industrial control networks. Emerson recommends that industry best practices are followed for network
segmentation and avoid exposing valve system or stand-alone systems with integrated fieldbus communication directly to
the internet. If external connections are available on the control network or control system, an appropriate firewall should
always be used.
Additionally, the following recommendations should be followed:
•Minimize internet and business network exposure for all control system devices and/or systems and ensure that
they are not accessible from the Internet.
•Locate control system networks and remote devices behind firewalls and isolate them from the business network.
•If remote access is required, only use secure methods such as Virtual Private Networks (VPNs) and recognize that
VPNs may have vulnerabilities and should always be updated to the most current version available. Also recognize
that a VPN is only as secure as the connected devices it serves.
•NETWORK SECURITY IS YOUR RESPONSIBILITY! It is the responsibility of every user to assess their
own level of risk with regards to the specific aspects of each application and determining appropriate
related action.
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Safety Precautions
Before using this product, please read this manual and the relevant manuals carefully and pay attention to safety and
product application. The following symbols are used in the manual to identify important safety, installation, and application
information.
The CAUTION symbol indicates a possible hazard which may cause injury or equipment damage. Please review and take
appropriate action.
The NOTE symbol indicates important information regarding equipment installation and setup. Please review and take
appropriate action.
Electrical Installation and Operational Guidelines
•AVENTICS valve systems with integrated fieldbus communications must only be connected to a
Class 2 power source.
•All AVENTICS communication nodes should be grounded during the installation process. Proper
grounding guidelines can be found in National Electrical code IEC 60204-1 or EN 60204-1.
•All AVENTICS G3 Electronics Products must only be installed or wired in accordance with ASCO
AVENTICS published instructions and applicable electrical codes.
•When using MULTIPLE CLASS 2 POWER SOURCES all sources shall be Listed and rated suitable for
parallel interconnection.
•All field wiring shall be suitable for Class 1, Electric Light and Power, or if Class 2, 3 wirings, such
wirings shall be routed separately and secured to maintain electrical and physical separation between
Class 2 wiring and all other class wiring and limited energy circuit conductors from unlimited energy
circuit conductors.
•When using Class 2 Device Wiring Only, you SHALL NOT Reclassify and Install as Class 1, 3 or Power
and Lighting Wiring.
•When using molded connector power cables, DO NOT RELY ON WIRE COLORS FOR PIN-OUT; Always
use pin number references.
•Wire connections shall be rated suitable for the wire size (lead and building wiring) utilized.
NOTE!
CAUTION
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Table of Contents
PAGE
1. About POWERLINKTM........................................................................................................................................5
1.1 Overview ...............................................................................................................................................5
1.2 580 POWERLINKTM Features .....................................................................................................................5
2. 580 POWERLINKTM Introduction.........................................................................................................................6
2.1 Pneumatic Valve Manifold –501 Series shown............................................................................................7
2.2 500 Series Manifold Stations ....................................................................................................................8
2.3 Z-Board™ Connectors .............................................................................................................................9
3. Zoned Power.....................................................................................................................................................10
3.1 503 Series Zoned Power application ........................................................................................................10
3.2 503 Series Zoned Power example ...........................................................................................................11
4. Communication Module ......................................................................................................................................12
4.1 580 POWERLINKTM Node ........................................................................................................................12
4.2 580 Node Description ............................................................................................................................13
4.3 Connector Pin-Outs ...............................................................................................................................14
4.4 Electrical Connections............................................................................................................................15
4.5 Chassis Ground ....................................................................................................................................16
4.6 Power Consumption ..............................................................................................................................17
4.7 Recommended External Fuses ................................................................................................................18
4.8 Diagnostics –580 POWERLINKTM Node LED Functions................................................................................19
5. Extended Coil Capability .....................................................................................................................................20
5.1 500 Series Extended Coil Configurations ..................................................................................................20
5.2 500 Series Extended IO Mapping ............................................................................................................23
5.3 501 Series, up to 64 solenoid coils..........................................................................................................24
5.4 501 Series, up to 128 solenoid coils ........................................................................................................25
5.5 502 and 503 Series, up to 80 coils ..........................................................................................................26
6. 580 POWERLINKTM Node Graphic Display ..............................................................................................................27
6.1 IP Address Sub-Menu ............................................................................................................................28
6.2 Subnet Mask Sub-Menu .........................................................................................................................29
6.3 Gateway IP ..........................................................................................................................................30
6.4 Web Server Sub-Menu...........................................................................................................................30
6.5 Config. Mode........................................................................................................................................32
6.6 MAC Address Sub-Menu.........................................................................................................................33
6.8 Model Number Sub-Menu.......................................................................................................................33
6.9 Advanced Settings –Comm. Fault...........................................................................................................34
6.10 Advanced Settings - Brightness ..............................................................................................................35
5.12 Advanced Settings –Flip Display ............................................................................................................36
5.13 Advanced Settings –Parameters Lock .....................................................................................................37
5.14 Advanced Settings –Configuration Lock ..................................................................................................38
6.12 Factory Defaults ...................................................................................................................................39
6.13 Diagnostics ..........................................................................................................................................40
6.14 Diagnostics Self-Test.............................................................................................................................40
6.15 Messages Error Messages ......................................................................................................................42
7. POWERLINKTM Integrated Web Server ..................................................................................................................43
7.1 Connecting to an Aventics 580 PowerlinkTM Node ......................................................................................43
7.2 Using the Functionality of the 580 PowerlinkTM Web Server.........................................................................45
7.3 User Configurable Device Parameters ......................................................................................................52
7.4 Communication Fault/Idle Mode Parameter ..............................................................................................53
8. B&R Automation Studio and 580 Configuration ......................................................................................................54
8.1 Import the XDD File ..............................................................................................................................54
9. POWERLINKTM Mapping.......................................................................................................................................61
9.1 I/O Sizes .............................................................................................................................................61
9.2 Bit Mapping Rules .................................................................................................................................61
9.3 Mapping Example No. 1 .........................................................................................................................62
9.4 Mapping Example No. 2 .........................................................................................................................63
10. Appendix ........................................................................................................................................................64
10.1 System Specifications............................................................................................................................64
10.2 Factory Default Settings ........................................................................................................................64
10.3 Troubleshooting....................................................................................................................................65
10.4 Glossary of Terms.................................................................................................................................65
10.5 Technical Support .................................................................................................................................66
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1. About POWERLINKTM
1.1 Overview
POWERLINKTM is an Ethernet-based networking solution for automation but has added benefits/features toward
manufacturing applications.
The Ethernet POWERLINKTM Standardization Group or EPSG develops and promotes POWERLINKTM technology.
POWERLINKTM uses industrial M12 IP67-rated connectors. The protocol transfers data at a fixed speed of 100 Mbps.
The maximum network cabling distance is limited to 100m segments at 20º C.
More information about POWERLINKTM can be obtained at the web site http://www.ethernet-powerlink.org.
1.2 580 POWERLINKTM Features
Features
Description
Spec. Supported
Designed by the Ethernet POWERLINKTM Standardization Group (EPSG)
Bus Topology
Star, Tree, Ring or Daisy Chain
Baud Rates Supported
100 Mbps
CE
CE Compliant
Duplicate Address Detection
If a duplicate address is detected on power up, duplicates will not
progress to run mode
Address Setting
Web Page Configuration, Graphical Display
Conformance Tested
EPSG proof of conformity
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2. 580 POWERLINKTM Introduction
The 580 POWERLINKTM Node is an electronic interface that features an integrated graphic display for simple
commissioning and displaying of diagnostic information. The 580 POWERLINKTM Node mates to a variety of valve
series including, the 501, 502, and 503. The 580 POWERLINKTM Node is capable of addressing a total of (32) coil
outputs, with diagnostic functionality built in. With proper assembly and termination the 580 POWERLINKTM Node has
an IP65 rating.
This manual describes specific information for configuring and commissioning the Aventics 580 POWERLINKTM Node.
For more information relating to pneumatic valves and valve manifold assemblies, please refer to the Aventics 501 and
503 Series catalogs at http://www.Emerson.com.
580 POWERLINK Node
Valve Side
Drives up to 32 coils
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2.1 Pneumatic Valve Manifold –501 Series shown
The pneumatic valve manifold with internal circuit board technology is modular. The valve solenoid coil connections
are automatically made using Z-Board™technology (plug together PC boards, which allow internal connection from
solenoid coils to output drivers without the use of wires). This allows easy assembly and field changes.
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2.2 500 Series Manifold Stations
Solenoid Coil Connections using Z-Board™ Technology for 50x valve series
Z-Board™ plug together technology connects all valve solenoids to the valve coil output driver board, located in the
valve adapter. There is a maximum of 128 coil outputs available on the complete manifold assemblies. The 128
available outputs are accessed on the 501 series valves utilizing 4 station manifolds and on the 502 and 503 series
utilizing 2 station manifolds.
14 Solenoid,
Pin No. 1
Common,
Pin No. 4
12 Solenoid,
Pin No. 2
Not Used,
Pin No. 3
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2.3 Z-Board™ Connectors
The 501/502/503 valve series utilize 2 different Z-Board™designs to achieve the single and double solenoid
output functions. This yields the possible 32 single, 16 double, or various combinations of valve coil output
capabilities. The 501 Z-Board™is minimum (4) stations, the 502 and 503 Z-Board™is minimum (2) stations.
501 Series
502 Series
503 Series
Each series Z-BoardTM can be selected in either SINGLE or DOUBLE output (coil) versions.
The SINGLE and DOUBLE output function cannot be mixed on the Z-BoardsTM
NOTE!
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3. Zoned Power
3.1 503 Series Zoned Power application
The Zoned Power Manifold blocks can be incorporated into a 503-manifold assembly to isolate
Power to a number of valve stations, independent from the main power of the manifold. This
is achieved by the integral 4 Pin M12 connector along with the modified manifold board. The
total number of Zoned Power Manifold blocks is determined by the maximum solenoid outputs
as defined by the type of interface (e.g. G3 Electronics, Terminal Strip, D-Sub). For user
flexibility, the Zoned Power Manifold blocks are available in both "proprietary" and "ISO"
versions and can be ordered with the M12 connector starting at the first or second station.
Technical Data
Electrical Data:
Voltage:
24 VDC (0 VDC must be common with main power)
Connection:
4 Pin M12 Single Key Male
Environmental:
IP65 (with proper connection)
V Wiring Option
W Wiring Option
W & V Connector Pin Out
V
W
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3.2 503 Series Zoned Power example
In the example shown below there are two Zoned Power Manifold blocks used. One is a "W" wiring option and the
other is a "V" wiring option. The first (5) stations of the manifold assembly get their power from the M12 4 Pin
connector at station one. The next (5) stations get their power from the M12 4 Pin connector at station six. Each of
these "Zones" can be individually switched of if the machine or process requires. This example is considered a
manifold with (2) Power Zones. The Main Power (7/8" MINI) cannot be considered or used as a Power Zone;
Switched Power (Solenoid/Output Power) MUST be present for control to the solenoids.
The 0 VDC reference for the +24 VDC applied to Pin 4 of the M12 connector MUST be the same
as the one used on G3/580/Terminal Strip/25 or 37 Pin Sub-D/19 or 26 Pin Round Connector.
If multiple 24 VDC power supplies are used the 0 VDC references of each supply MUST be
common.
NOTE!
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4. Communication Module
4.1 580 POWERLINKTM Node
This module is the communication interface to the manifold. It contains communication electronics and internal short
circuit protection for power. It can be configured via the graphic display or via software
Communication Interface
Part Number
580 POWERLINKTM Node
P580AEPL1010A00
580 POWERLINKTM Node w/DIN Rail
P580AEPL1010DRM
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4.2 580 Node Description
Detail No.
Description
1
Link /Activity LED
2
5 Pin M12 Female Communication Connector per PTO specification
3
5 Pin M12 Female Communication Connector per PTO specification
4
Mounting Hole
5
5 Pin M12 Male Power Connector
6
Link / Activity LED
7
ERR LED
8
STAT LED
9
SET Button –used to navigate through user menus and to set parameters
10
Graphic Display –used to display parameter information
11
NEXT Button –used to navigate through user menus and to set parameters
9
4
3
8
2
5
7
6
1
10
11
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4.3 Connector Pin-Outs
Industry standard connectors are used for communication and power. The POWERLINKTM communication connectors
are (2) M12 D-Coded 4 pin female connectors. The Power connector is an M12 5 pin male connector.
POWERLINKTM Communication Connector Pin-Out
Pin No.
Function
Description (FEMALE)
1
TD+
Positive Transmit Line
2
RD+
Positive Receive Line
3
TD-
Negative Transmit Line
4
RD-
Negative Receive Line
Power Connector Pin-Out
Pin No.
Function
Description (MALE)
1
+24 VDC (Node)
Voltage used to power node electronics UNSW
2
0 VDC Common (Valves)
0 VDC Voltage used to power outputs (Valves) SW
3
0 VDC Common (Node)
0 VDC Voltage used to power node electronics UNSW
4
+24 VDC (Valves)
Voltage used to outputs (Valves) SW
5
FE
Functional Earth
!
•Power common (0 VDC) pins 2 and 3 are isolated from each other to allow separate
(isolated) power supply connection if required. However, they can be connected together if a
single common, non-isolated, application is preferred.
•The current draw of the +24VDC Valves (Pin 4) and +24VDC Node (Pin 1), pins cannot
exceed 4 Amps, at any given moment in time.
•The Node pins supplies power to the node electronics. These pins must be powered at all
times for communication node to be functional.
•To be connected to Class 2 power source only
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4.4 Electrical Connections
Standard Power Connector Wiring Diagram Examples
Single Power Supply Example (Non-isolated commons)
Separate Power Supply Example (Isolated commons)
•Please see page 3-18 for external fuse sizing guide.
•When using molded connector power cables, Do Not rely on wire colors for
Pin-Out. Always use pin number references.
•To be connected to a Class 2 power source only
•Class 2 Device Wiring Only –Do Not Reclassify and Install as Class 1, 3 or
Power and Lighting Wiring.
•Wire connections shall be rated suitable for the wire size (lead and building
wiring) employed.
•CLASS 2 WIRING: All filed wiring shall be suitable for class 1, Electric Light
and Power, or Class 2, Class 3 wirings are routed separately and secured to
maintain separation between 1) Class 2 wiring and all other class wiring, and
2) limited energy circuit conductors from unlimited energy circuit
conductors.
•MULTIPLE CLASS 2 POWER SOURCES: when interconnects, Class 2 sources
shall be listed and rated suitable for parallel interconnection.
!
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4.5 Chassis Ground
All Aventics manifolds should be grounded for safety. Grounding guidelines can be found in National Electrical code IEC
60204-1 or EN 60204-1.
CHASSIS GROUND CONNECTION POINT,
501 VALVES
CHASSIS GROUND CONNECTION
POINT, 502 & 503 VALVES
•When grounding to a machine frame, please ensure that the machine frame itself is
already properly grounded.
•Better grounding can be achieved when larger diameter (lower gauge) wire is used.
CAUTION
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4.6 Power Consumption
Power Connection
Pin No.
Function
Description
1
+24 VDC (Node)
Voltage used to power node electronics UNSW
2
0 VDC Common (Valves)
0 VDC Voltage used to power outputs (Valves) SW
3
0 VDC Common (Node)
0 VDC Voltage used to power node electronics UNSW
4
+24 VDC (Valves)
Voltage used to outputs (Valves) SW
5
FE
Functional Earth
Power Rating
•The maximum system current capability is 4 Amps.
Component
Voltage
Tolerance
+24VDC
(Valve)
Pins 2 and 4
+24VDC
(Node)
Pins 1 and 3
Current
Power
Current
Power
Solenoid Valve Coil 501 (Each)
24 VDC
+10%/-15%
0.03 Amps
0.8 Watts
NA
NA
Solenoid Valve Coil 502 (Each)
24 VDC
+10%/-15%
0.04 Amps
1.0 Watts
NA
NA
Solenoid Valve Coil 503 (Each)
24 VDC
+10%/-15%
0.07 Amps
1.7 Watts
NA
NA
580 POWERLINKTM Node
24 VDC
+/- 10%
NA
NA
0.110 Amps
2.64 Watts
•Do not exceed 4 amps of current through the M12 Power connector.
!
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4.7 Recommended External Fuses
External fuses should be chosen based upon the physical manifold configuration. Please refer to table below for
the fuse sizing chart.
External Fuse Sizing Chart
Power Consumption - Power Connector Pin for VALVES
Description
Current
Number of Solenoid Valve Coils Energized Simultaneously
___ X 0.03 A (501 Series)
=
__________Amps
___ X 0.04 A (502 Series)
=
__________Amps
___ X 0.07 A (503 Series)
=
__________Amps
Total:
__________Amps
Surge Compensation:
X
1.25
Suggested External +24 VDC (Valves) Fuse Value:
__________Amps
Power Consumption –Power Connector Pin for NODE
Description
Current
Communication Node Power Consumption
=
0.110 Amps
Surge Compensation:
X
1.25
Suggested External Pin +24 VDC (Node) Fuse Value:
0.1375 Amps
•
The Node Power pins supply power to the node electronics. These pins must always be
powered for the communication node to be functional.
•
Reverse polarity protection is provided.
NOTE!
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4.8 Diagnostics –580 POWERLINKTM Node LED Functions
Upon power up the STAT, ERR, L/A1and L/A2LEDs indicate the state of the unit and the network connections. There
are four LEDs on the 580 POWERLINKTM node. The LEDs functions are described in the table below.
LED Name
Color
Status
Description
STAT
Green
ON
PowerlinkTM connection established
FLASHING -100ms
No PowerlinkTM connection
FLASHING - 500ms
Lost an established PowerlinkTM connection
ERR
Off
OFF
No Error
Red
ON
Lost an established PowerlinkTM connection
L/A1
Off
OFF
Ethernet connection is not detected
Green
ON
The module is connected to an Ethernet network
FLASHING –
100ms
PowerlinkTM Data is being sent / received by the node
L/A2
Off
OFF
Ethernet connection is not detected
Green
ON
The module is connected to an Ethernet network
FLASHING- 100ms
PowerlinkTM Data is being sent / received by the node
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5. Extended Coil Capability
Below is a list of the minimum firmware level that support the Extended Coil Manifolds.
Module firmware revision levels can be confirmed in the integrated graphic display and the built-in web
browser. See pg. Error! Bookmark not defined. for more information.
5.1 500 Series Extended Coil Configurations
The Extended Coil Manifold can be configured to control 3 additional extended coil valve driver assemblies;
unless already configured from the factory. Modify the configuration with either the graphic display interface
as shown on page 32 or using the integrated web server configuration page shown on page 21.
Extended Solenoid Coil Capability requirements:
Module
Part Number
Firmware
Communication Module
P580AEPN1010A00
Rev 2.001 Build 43054
Valve Series
Number of Extended
Coil Valve Drivers
Total number of coils
Configuration
Selection
Allocated number of I/O
Bytes designated for
valves
501
0
3-32
32 coils
4
1
33-64
64 coils
8
2
65-96
96 coils
12
3
97-128
128 coils
16
502/503
0
1-32
32 coils
4
1
33-48
64 coils
8
2
49-64
64 coils
8
3
65-80
96 coils
12
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